Opto-mechanical coupler

ABSTRACT

An opto-mechanical coupler and corresponding method are provided. The coupler may include a first end and a second end configured to receive optical fibers and a top surface and bottomed surface defining a through hole extending between the top and bottom surfaces. The coupler may include a reflective surface that redirects the optical signals between a first direction and a second direction substantially perpendicular to the first direction. The coupler may position one or more optical fibers along a second direction such that an optical signal from the plurality of optoelectronic transceivers is directed into one or more optical fibers or an optical signal from the one or more optical fibers is directed into a plurality of the optoelectronic transceivers, with the coupler accommodating different diameters of optical fiber including POF, SMF, and/or MMF fiber.

FIELD OF THE INVENTION

The present disclosure relates generally to optoelectronic interfacesfor transmitting optical signals through fiber optic cable systems and,more particularly, to apparatuses and associated methods of couplingfiber optic cables with optoelectronic transceiver assemblies fortransmitting optical signals via fiber optic cables.

BACKGROUND OF THE INVENTION

Optical fibers are thin filaments cladded in a material with a low indexof refraction capable of transmitting optical signals. Various types ofoptical fibers are present in the art including plastic/polymer opticalfiber (POF), single mode optical fiber (SMF), and multi-mode opticalfiber (MMF). Traditionally, POFs are comprised of thin plastic orpolymer fibers and are often utilized in short distance applications.Conversely, SMFs are comprised of thin glass fibers and are oftenutilized in longer distance and high speed applications. MMFs areconfigured similarly to SMFs, but are designed to carry multiple modesof optical signals at the same time, each signal being transmitted at aslightly different reflection angle. Unlike SMFs, which can carryoptical signals over long distances, MMFs are typically used for shortertransmission distances.

Optical fibers may thus serve as the transmission media for opticalsignals generated by optoelectronic transceivers. For example, opticalfibers are often used in conjunction with various types oflight-emitting components, which generate the optical signal based on anelectrical input for transmission through the fibers. Often, forexample, vertical-cavity surface-emitting lasers (VCSELs) are used toemit light through the fiber optic cables. Other sources of lightinclude edge emitting lasers, edge emitting silicon phontoicscomponents, collimated VCSELs, lens integrated surface emitting lasers(LISELs), and other sources.

Applicant has identified a number of deficiencies and problemsassociated with conventional optical fiber couplers, interfaces, andother associated systems. Through applied effort, ingenuity, andinnovation, many of these identified problems have been solved bydeveloping solutions that are included in embodiments of the presentinvention, many examples of which are described in detail herein.

BRIEF SUMMARY OF THE INVENTION

Opto-mechanical couplers are therefore herein described that areconfigured to accommodate multiple fibers of different types (e.g.,different fiber diameters) without requiring major system modification.

In one embodiment, an opto-mechanical coupler is provided that includesa body defining a first end and a second end, wherein the first end isconfigured to receive one or more optical fibers. The coupler furtherincludes a bottom surface supporting a plurality of optical lenses, withthe optical lenses configured to allow passage of optical signalstraveling in a first direction for transmission to or from a pluralityof optoelectronic transceivers disposed proximate the bottom surface.The coupler may further include a top surface opposite the bottomsurface.

The body defines at least one through-hole extending between the topsurface and the bottom surface, and the through-hole is configured toreceive a pin therethrough. The coupler further includes a reflectivesurface configured to redirect the optical signals between the firstdirection and a second direction substantially perpendicular to thefirst direction. The coupler may thus be configured to position the oneor more optical fibers along the second direction such that an opticalsignal from the plurality of optoelectronic transceivers is directedinto the one or more optical fibers or an optical signal received fromthe one or more optical fibers is directed into the plurality of theoptoelectronic transceivers.

In some cases, the first end may define grooves configured to locateeach optical fiber at a height relative to a first optical path in thesecond direction. The first end may be configured to receive a first setof one or more optical fibers having a first diameter, and the secondend may be configured to receive a second set of one or more opticalfibers having a second diameter. In this regard, the first diameter andthe second diameter are not equal. The first end may define groovesconfigured to locate each optical fiber at a height relative to a firstoptical path in the second direction, and the second end may definegrooves configured to locate each optical fiber at a second heightrelative to a second optical path in the second direction, where thefirst height and the second height are not equal.

The first end, in some cases, may further comprise an apertureconfigured to receive an optical fiber, and the aperture may define adistal diameter and a proximal diameter, with the proximal diameterbeing smaller than the distal diameter. In some cases, the one or moreoptical fibers may be plastic optical fibers or single mode (ormulti-mode) optical fibers. Moreover, the coupler may be configured toreceive optical signals having a nominal wavelength of 1310 nm.

In other embodiments, an opto-mechanical coupler is provided thatincludes a body defining a first end and a second end, wherein the firstend comprises an aperture configured to receive one or more opticalfibers, and wherein the aperture defines a distal diameter and aproximal diameter, the proximal diameter being smaller than the distaldiameter. The coupler further includes a bottom surface configured tosupport a plurality of optical lenses, wherein the optical lenses areconfigured to allow passage of optical signals traveling in a firstdirection for transmission to or from a plurality of optoelectronictransceivers disposed proximate the bottom surface, and further includesa top surface opposite the bottom surface. The coupler also includes areflective surface configured to redirect the optical signals betweenthe first direction and a second direction substantially perpendicularto the first direction. The aperture is configured such that the one ormore optical fibers may be inserted into the aperture a distance basedon the diameter of the one or more optical fibers. Moreover, the one ormore optical fibers are positioned such that an optical signal travelingin the second direction from the plurality of optoelectronictransceivers is directed via the reflective surface into the one or moreoptical fibers or an optical signal from the one or more optical fibersis directed via the reflective surface into the plurality of theoptoelectronic transceivers.

In some cases, the aperture may define a first distance in the seconddirection having a constant diameter and a second distance in the seconddirection, wherein the diameter of the aperture over the second distanceis tapered between the distal diameter and the proximal diameter. Theone or more optical fibers may be plastic optical fibers or single modeoptical fibers, and the coupler may be configured to receive opticalsignals having a nominal wavelength of 1310 nm.

In still other embodiments, a method of manufacturing opto-mechanicalcouplers is also provided, where the method includes forming a bodydefining a first end, a second end, a bottom surface, a top surface, anda reflective surface, as described above. At least one aperture may bedefined proximate the first end, wherein the aperture is configured toreceive one or more optical fibers. A plurality of optical lenses may besupported via the bottom surface of the body, with the optical lensesconfigured to allow passage of optical signals traveling in a firstdirection for transmission to or from a plurality of optoelectronictransceivers disposed proximate the bottom surface. As described above,at least one through-hole may be defined extending between the topsurface and the bottom surface, and the through-hole may be configuredto receive a pin therethrough. The reflective surface may be configuredto redirect the optical signals between the first direction and a seconddirection substantially perpendicular to the first direction. In thisway, the coupler may be configured to position the one or more opticalfibers along the second direction such that an optical signal from theplurality of optoelectronic transceivers is directed into the one ormore optical fibers or an optical signal received from the one or moreoptical fibers is directed into the plurality of the optoelectronictransceivers.

In some cases, as described above, the apertures of the first end maycomprise grooves configured to locate each optical fiber at a heightrelative to a first optical path in the second direction. The first endmay be configured to receive via the apertures a first set of one ormore optical fibers having a first diameter. In some embodiments, themethod may further comprise defining additional apertures proximate thesecond end, where the additional apertures are configured to receive asecond set of one or more optical fibers having a second diameter. Inthis regard, the first diameter and the second diameter are not equal,such that fibers having different diameters may be received by arespective end and apertures of the coupler.

In some cases, the apertures of the first end may comprise groovesconfigured to locate each optical fiber at a height relative to a firstoptical path in the second direction, and the apertures of the secondend may comprise grooves configured to locate each optical fiber at asecond height relative to a second optical path in the second direction,wherein the first height and the second height are not equal. Eachaperture of the first end may define a distal diameter and a proximaldiameter, and the proximal diameter may be smaller than the distaldiameter.

The one or more optical fibers may be plastic optical fibers or singlemode (or multi-mode) optical fibers, and the coupler may be configuredto receive optical signals having a nominal wavelength of 1310 nm.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Having thus described the invention in general terms, reference will nowbe made to the accompanying drawings, which are not necessarily drawn toscale, and wherein:

FIG. 1 illustrates a perspective view of an opto-mechanical coupler, inaccordance with some embodiments discussed herein;

FIG. 2 illustrates a top view of the opto-mechanical coupler of FIG. 1,in accordance with some embodiments discussed herein;

FIG. 3 illustrates a bottom view of the opto-mechanical coupler of FIG.1, in accordance with some embodiments discussed herein;

FIG. 4 illustrates a perspective view of the opto-mechanical coupler ofFIG. 1, in accordance with some embodiments discussed herein;

FIG. 5 illustrates a perspective view of the opto-mechanical coupler ofFIG. 1 in conjunction with an optoelectronic transceiver system andoptical fibers, with a portion of the coupler removed, in accordancewith some embodiments discussed herein;

FIG. 6 illustrates a top view of the opto-mechanical coupler of FIG. 5with a portion removed, in accordance with some embodiments discussedherein;

FIG. 7 illustrates a cross-sectional side view of the opto-mechanicalcoupler of FIG. 5, in accordance with some embodiments discussed herein;

FIG. 8 illustrates a perspective view of an opto-mechanical coupler, inaccordance with some embodiments discussed herein;

FIG. 9 illustrates a top view of the opto-mechanical coupler of FIG. 8,in accordance with some embodiments discussed herein;

FIG. 10 illustrates a perspective view of the opto-mechanical coupler ofFIG. 8 in conjunction with a transceiver system and optical fibers, witha portion of the coupler removed, in accordance with some embodimentsdiscussed herein;

FIG. 11 illustrates a cross-sectional side view of the opto-mechanicalcoupler of FIG. 8 in conjunction with an optoelectronic transceiversystem and optical fibers, in accordance with some embodiments discussedherein;

FIG. 12 illustrates a perspective view of an opto-mechanical coupler, inaccordance with some embodiments discussed herein;

FIG. 13 illustrates a bottom view of the opto-mechanical coupler of FIG.12, in accordance with some embodiments discussed herein;

FIG. 14 illustrates a perspective view of the opto-mechanical coupler ofFIG. 12 in conjunction with an optoelectronic transceiver system andoptical fibers, with a portion of the coupler removed, in accordancewith some embodiments discussed herein; and

FIG. 15 illustrates a cross-sectional side view of the opto-mechanicalcoupler of FIG. 12 in conjunction with a transceiver system and opticalfibers, in accordance with some embodiments discussed herein.

DETAILED DESCRIPTION Overview

Optical cables are comprised of optical fibers. Optical cables may beutilized in conjunction with optical transmitters and receivers builtinto transceiver modules and systems located at the ends of the opticalcables for transmitting and receiving the optical communication signalscarried by the fibers. The transceiver modules may include smallform-factor pluggable (SFP) transceivers or dual SFP transceivers. Thetransceiver modules or systems may plug into suitable electricalcommunication ports, such as Gigabit Ethernet or InfiniBand® ports, ofswitching and computing equipment. Optoelectronic and opto-mechanicalcomponents in the transceiver modules and systems may convert thehigh-speed electrical signals output by the ports into optical signalsfor transmission over the fibers. In addition, these components mayconvert the optical signals received over the fibers into high-speedelectrical signals for input to the ports.

In many transceiver modules and systems, laser diodes, such as VCSELs,are used to generate optical signals for transmission over opticalfibers. VCSELs in particular are favored for their high bandwidth andefficiency. In some implementations, an array of such VCSELs is used todrive a corresponding array of optical fibers, which are joined togetherin a ribbon configuration. Optical fibers may be connected to bothVCSELs and photodiode configurations on opposing ends such that one ormore photodiodes may receive the light from the VCSELs and convert theincident light into electrical signals. One or more sources may providethe electrical signals for transmission from a transmitting device orreceiving the electrical signals after receipt from the transmittingdevice, and each source may be associated with one or more VCSELs and/orphotodiodes. The sources may provide electrical signals to the VCSELs,for transmission via optical fibers or may receive electrical signalsreceived by the photodiodes via optical fibers.

In order to properly align optical fibers for receiving or transmittingoptical signals, opto-mechanical couplers may be utilized. Thesecouplers position the optical fibers such that the optical signalsconverted by laser diodes, such as VCSELs, properly enter the opticalfibers in order to achieve effective transmission of the opticalsignals. opto-mechanical couplers may be utilized at both ends of anoptical cable and facilitate positioning optical fibers for transmittingand receiving optical signals.

As noted above, POFs are often utilized for short distance applicationsand provide accurate signals when used in shorter distance applicationsthan when utilized in long distance applications. POFs have a tighterbend radius and are more resilient due to the flexibility of the plasticor polymer utilized as the filament. Thus, POFs are often consideredmore user-friendly and are often easier to connect and install ascompared to SMFs. POFs are often lighter in weight and cheaper thanSMFs, but POFs are typically larger in diameter than SMFs. In contrast,SMFs are often used in long distance and high speed applications due toproviding more accurate signals than POFs. SMFs are resistant toflexibility and accidental breakage due to their stiffness and are oftenmore mechanically protected than POFs. Both POFs and SMFs haveadvantages often tailoring their utilization to specific applications.

Conventional opto-mechanical couplers and interfaces, however, areprimarily designed to accommodate a single type or diameter of opticalfiber in order to ensure proper optical interfacing between thetransceiver system and the optical fiber. Traditionally, a new, separatetransceiver was necessary when changing between optical fiber types,requiring large inventories of costly components and/or investment innew hardware.

Embodiments of the present invention that are described hereinbelowprovide opto-mechanical couplers capable of interfacing with opticalfibers of differing types, such as POFs and SMFs. The opto-mechanicalcoupler may be connected with one or more optical fibers, sometimesreferred to as a ribbon, and a transceiver module or system. The opticalfibers may operate as a medium by which optical signals may betransmitted over a specified distance. The transceiver module mayconvert received electrical signals into optical signals or opticalsignals into electrical signals, by way of one or more VCSELs orphotodiodes, respectively. In some embodiments, the opto-mechanicalcoupler may have one or more reflective surfaces such that the path ofthe optical signals may be directed between the transceiver module andthe optical fibers. Embodiments of the opto-mechanical coupler describedherein may position and align one or more optical fibers in the properlocation and direction to transmit or receive optical signals directedvia the one or more reflective surfaces. In order to operate with bothPOFs and SMFs, the opto-mechanical coupler may utilize means hereinafterdescribed.

In some embodiments, at least one end of the opto-mechanical coupler maybe capable of receiving optical fibers of varying diameters, such asthose common to POFs and SMFs, by utilizing a grooved surface. In suchan embodiment, at least one end of the opto-mechanical coupler mayinclude grooves in the surface for receiving optical fibers. Thesegrooves may be configured such that a POF or SMF of a set diameter willbe aligned to the proper height for receiving an optical signal for therespective fiber. In such an embodiment, two prisms in separateopto-mechanical couplers may be utilized. Each prism may be configuredfor use with a single type of fiber and may be configured such that theoptical signals produced by the transceiver module may be directed to analigned optical fiber.

In some embodiments, each end of the opto-mechanical coupler may becapable of receiving optical fibers of a specific diameter, such asthose common to POFs and SMFs, by utilizing a grooved surface. Forexample, the first end may be configured to receive POFs, while thesecond end may be configured to receive SMFs. In such an embodiment, theappropriate side of the opto-mechanical coupler may be utilizeddepending on the optical fiber used in the application. If another typeof optical fiber is needed in the application, the orientation of theopto-mechanical coupler may be reversed such that the opposite end isused to receive the optical fibers. In such an embodiment, tworeflective surfaces may be used such that each reflective surface isconfigured to align the optical signals at a position appropriate forits respective fiber (e.g., POF or SMF).

In some embodiments, at least one end of the opto-mechanical coupler maybe capable of receiving optical fibers of varying diameters, such asthose common to POFs and SMFs, by utilizing a tapered aperture. In suchan embodiment, at least one end of the opto-mechanical coupler may havean aperture for receiving optical fibers. This aperture may extendthrough the body of the opto-mechanical couple and may vary in diameter,with a smaller proximal diameter closest to the transceiver module orsystem, and a larger distal diameter farther from the transceivermodule. In such an embodiment, optical fibers of varying diameters mayonly be inserted into the aperture a set distance until the aperturenarrows to a diameter less than or equal to the diameter of the opticalfiber. This aperture may be configured such that a POF or SMF of a setdiameter may only be inserted into the aperture a set distance, with theaperture configured to align the fiber at the proper height forreceiving an optical signal for the respective fiber.

For the sake of clarity and convenience of description, the embodimentsthat are described below refer to a particular optical cableconfiguration, using VCSELs as emitters and certain types of switchingelements. The principles of the present invention, however, maysimilarly be implemented using other types of emitters and switchingelements, as well as other optoelectronic transceiver components (e.g.,photodiodes and differently configured optical cables and connectormodules).

Coupling Mechanisms

With reference to FIG. 1, an opto-mechanical coupler according to oneembodiment is illustrated. As shown in FIG. 1, an opto-mechanicalcoupler 100 may have a first end 105, a second end 110, a top surface115, a bottom surface (bottom surface 300 in FIG. 3), a reflectivesurface 120, and a through-hole 125. As described in greater detailbelow, the first end 105 may be configured so that one or more opticalfibers may be properly aligned with the reflective surface 120 totransmit or receive optical signals.

With continued reference to FIG. 1, the first end 105 may be configuredto receive one or more optical fibers. Optical fibers may be insertedinto the opto-mechanical coupler 100 via the first end 105 such that anend of each fiber is disposed proximate the reflective surface 120. Forexample, the first end 105 of the opto-mechanical coupler may in someembodiments be grooved (e.g., channeled, ribbed, ridged, etc.) such thatone or more optical fibers may be pressed down into the respectivegrooves of the opto-mechanical coupler 100 and thereby aligned with thereflective surface 120 to properly receive optical signals.

The reflective surface 120 may be configured to redirect optical signalssuch that the optical signals are aligned with the one or more opticalfibers. In some embodiments, the reflective surface 120 may receiveoptical signals from at least one transceiver module or system. Thetransceiver module (shown as transceiver module 515 in FIGS. 5-7) may,for example, be configured to convert electrical signals into opticalsignals through the use of one or more VCSELs. The VCSELs may emitoptical signals in a direction substantially perpendicular to thedirection in which the one or more optical fibers may be oriented, asdepicted in the figures. The reflective surface 120 may be configured tochange a pathway of the optical signals, by reflecting the opticalsignals that are incident to the reflective surface 120, therebyredirecting them by a certain angle. In some embodiments, the reflectivesurface 120 may redirect optical signals such that they travel in adirection that is substantially perpendicular to the direction theoptical signals are initially transmitted by the one or more VCSELs. Inthis regard, the reflective surface 120 may be comprised of anyreflective material suitable for use in optoelectronics (e.g., prisms,mirrors, among others).

The transceiver module 515 may also be configured to convert opticalsignals into electrical signals through the use of one or morephotodiodes. The photodiodes may receive optical signals from the one ormore optical fibers. The reflective surface 120 may be configured tochange a pathway of the optical signals, by reflecting the opticalsignals that are incident to the reflective surface 120, therebyredirecting them by a certain angle. In some embodiments, the reflectivesurface 120 may redirect optical signals such that they travel in adirection towards the photodiode(s) that is substantially perpendicularto the direction the optical signals are transmitted through the one ormore optical fibers as a result of the reflective surface.

The top surface 115 and the bottom surface (bottom surface 300 shown inFIG. 3) of the opto-mechanical coupler 100 may define a through-hole125. In order to ensure that the optical signals are properly positionedto align the one or more optical fibers with the optoelectronictransceiver modules, the opto-mechanical coupler 100 may be secured to aprinted circuit board or substrate supporting the optoelectronictransceivers 515 such that the one or more optical fibers cannot moverelative to the optoelectronic transceivers. For example, thethrough-hole 125 may be configured to receive a pin as a means forsecuring the opto-mechanical coupler 100. Although the depictedembodiment shows two through-holes 125 capable of receiving pins forsecuring the opto-mechanical coupler 100, the present disclosurecontemplates any number of through-holes for receiving one, two, or morepins, and in other embodiments may include different means for securingan opto-mechanical coupler 100 (e.g., pins, snaps, or clamps, amongothers).

With reference to FIGS. 2-4, embodiments of the opto-mechanical coupler100 may have a bottom surface 300 configured to support a plurality ofoptical lenses 200. In some embodiments, a plurality of transceivermodules may be positioned proximate the bottom surface 300 of theopto-mechanical coupler 100. In order for the optical signals to passbetween the transceiver module or system and the one or more opticalfibers for transmission, the optical lenses 200 supported by/within thebottom surface 300 may be configured to allow optical signals generatedby the optoelectronic transceivers 515 (e.g., VCSELs) to pass throughthe bottom surface 300 and be directed to the reflective surface 120 forredirection to the core of an optical fiber 510. Likewise, opticalsignals traveling through the optical fiber 510 and hitting thereflective surface 120 may be redirected through the optical lenses 200to reach the optoelectronic transceiver (e.g., a photodiode). In somecases, for example, the optical lenses 200 are embedded in the materialof the opto-mechanical coupler 100, such as proximate the bottom surface300.

With reference to FIGS. 5-7, an opto-mechanical coupler 100 according toone embodiment is depicted in conjunction with a substrate 500, two pins505, optical fibers 510, a plurality of transceiver modules 515, and twodrivers 520. A substrate 500 may be utilized in conjunction with pins505 in some opto-mechanical coupler embodiments as a means for securingthe opto-mechanical coupler 100 with respect to the optoelectronictransceiver 515 and the one or more optical fibers 510. As describedabove, one or more through-holes 125 may be configured to receive one ormore pins 505 to secure the opto-mechanical coupler 100 from movementsuch that the one or more optical fibers 510 are properly aligned fortransmitting or receiving optical signals. Conversely, in otherembodiments, the pins 505 or similar fastening structures may form apart of the opto-mechanical coupler 100 (e.g., may be attached to theopto-mechanical coupler or extend from the opto-mechanical coupler, notshown) and may be received via openings defined the substrate 500 towhich the opto-mechanical coupler 100 is mounted.

As depicted in FIGS. 5-7, one or more optical fibers may be positionedand aligned via grooves disposed through the first end 105. Althoughdepicted with optical fibers of a certain diameter in FIG. 5-7, thepresent disclosure contemplates that the grooves defined by the firstend 105 may be configured to accommodate optical fibers of any typeand/or diameter, including POFs, SMFs, and MMFs, as would be understoodby one or ordinary skill in the art in light of this disclosure.Additionally, the opto-mechanical coupler 100 may be configured tooperate with optical signals transmitted through POFs at a nominalwavelength of 1310 nm and/or, alternatively, at nominal wavelengths of850 nm and 1550 nm. Although described in conjunction with opticalsignals at a wavelength of 1310 nm, 850 nm, and/or 1550 nm, the presentdisclosure contemplates small variations in wavelength that are commonto optical transmissions. The present disclosure contemplates utilizingoptical signals at any wavelength as would be suitable for transmissionvia one or more POFs, SMFs, or MMFs.

One or more optical fibers 510 may be positioned via grooves disposed atthe first end 105. The grooves may operate to align the core of the oneor more optical fibers 510 to the correct height relative to the desiredoptical path of the optical signals with respect to the reflectivesurface 120. The grooves may, for example, have a v-shaped cross-sectionand extend partially through the body of the opto-mechanical coupler 100to a distance proximate the reflective surface 120. The circularcross-section of the one or more optical fibers may rest in the groovessuch that the core of the optical fiber is correctly aligned (e.g.,positioned at the right height) with the desired optical path of theoptical signals.

In some cases, different reflective surfaces 120 may be needed toaccommodate optical fibers having different cross-sectional diameters.For example, an optical fiber with a larger diameter (e.g., a POF) maybe aligned by the grooves of the first end 105 to a first heightappropriate for directing an optical signal to or from a firstreflective surface, while an optical fiber with a smaller diameter(e.g., an SMF) may be aligned by the grooves of the first end 105 to asecond height appropriate for directing an optical signal to or from asecond reflective surface. Because the heights differ when placed in thesame groove configuration due to the different diameters of the opticalfibers, two reflective surfaces (e.g., prisms) in separateopto-mechanical couplers 100 may be utilized, and the user may switchbetween the different opto-mechanical couplers 100 when switchingbetween optical fiber types, such as by removing the pins of aninstalled opto-mechanical coupler and replacing it with a differentopto-mechanical coupler via the pins.

The embodiment described above with reference to FIGS. 1-7 provides anopto-mechanical coupler 100 that is configured to accommodate a singletype of fiber (e.g., a particular fiber diameter) corresponding to thesize, shape, and positioning of the apertures (e.g., v-shaped grooves)of the first end 105 with respect to the position and orientation of thereflective surface 120 defined by the coupler body. Thus, when switchingbetween different types of fibers (e.g., between SMF, MMF, and POF orbetween different fiber diameters), one opto-mechanical coupler 100would need to be switched out with another, differently sizedopto-mechanical coupler, as described above.

With reference to FIGS. 8-9, however, other embodiments provide anopto-mechanical coupler that is configured to accommodate two or moredifferent types or diameter-size of fiber, eliminating the need toswitch out couplers when changing between fibers. Rather, even when oneset of fibers having a first diameter is switched out with a second setof fibers having a second, different diameter, the same opt-mechanicalcoupler may be used, with the coupler configured as described below suchthat regardless of the fiber diameter, the light from the source isautomatically aligned with the core of the fiber by virtue of theconfiguration of the coupler as described below.

As shown in FIG. 8, an opto-mechanical coupler 800 according to one suchembodiment may have a first end 805, a second end 810, a top surface815, a bottom surface (bottom surface 860 in FIG. 11), two reflectivesurfaces 820, one or more through-holes 825, and a plurality of opticallenses 830 supported via the bottom of the coupler. As described ingreater detail below, the first end 805 may be configured such that oneor more optical fibers of one type may be properly aligned with areflective surface 820 to transmit or receive optical signals, while thesecond end 810 may be configured so that one or more optical fibers ofanother type may be properly aligned with a reflective surface 820 totransmit or receive optical signals.

With continued reference to FIGS. 8-9, the opto-mechanical coupler 800may have a first end 805 configured to receive one or more opticalfibers of a first type or of a first diameter. The optical fibers of thefirst type/diameter may be inserted into the opto-mechanical coupler 800through the first end 805 such that an end of each fiber is disposedproximate the reflective surface 820 configured for redirecting opticalsignals via one or more optical fibers of the first type. In someembodiments, the opto-mechanical coupler 800 may have a second end 810configured to receive one or more optical fibers of a second type or ofa second diameter. The optical fibers of the second type/diameter may beinserted into the opto-mechanical coupler 800 through the second end 810such that an end of each fiber is disposed proximate the reflectivesurface 820 configured for redirecting optical signals via one or moreoptical fibers of a second type. By way of example, the first end 805may be configured to align POFs, while the second end 810 may beconfigured to align SMFs. Depending on the type of optical fiber that isto be used, the user may install the opto-mechanical coupler such thatthe appropriate end is accessible and can be used to receive the opticalfibers. If later a different type of optical fiber is desired, theopto-mechanical coupler 800 may be unsecured (e.g., by removing the pinsas described above) and its orientation may be reversed to provideaccess to the other end. Likewise, if the same type of fiber (e.g.,POF), but having a different fiber diameter, is desired (e.g., larger orsmaller), the opto-mechanical coupler 800 may be reversed as describedabove to provide access to the other end, which may be sized toaccommodate the different diameter. As still another example, one sideof the opto-mechanical coupler 800 may be configured to accommodate SMF,while the other is configured to accommodate MMF. In this way, a singleopto-mechanical coupler may be capable of accommodating optical fibershaving different diameters.

As discussed above, in some embodiments, the opto-mechanical coupler 800may have two reflective surfaces 820 each configured to align opticalsignals for transmission via one or more optical fibers of a certaintype. By way of example, the reflective surface 820 positioned closestto the first end 805 may be configured (e.g., sized, shaped, positioned,etc.) to align optical signals for transmission via one or more POFs,while the reflective surface 820 closest to the second end 810 may beconfigured to align optical signals for transmission via one or moreSMFs.

The top surface 815 and the bottom surface (bottom surface 860 in FIG.11) may define one or more through-holes 825, as described above withreference to FIGS. 1-3. The opto-mechanical coupler 800 may have abottom surface 860 configured to support a plurality of optical lenses830. As described above with reference to FIGS. 2-4, a plurality oftransceiver modules may be positioned proximate the bottom surface 860of the opto-mechanical coupler 800, such that the optical signals canpass between the transceiver module or system and the respectivereflective surface 820 via the optical lenses 830.

As depicted in FIGS. 10-11, one or more optical fibers may be received,secured, and aligned via the first end 805 or via the second end 810.Although depicted with optical fibers of a certain diameter in FIG.10-11, the present disclosure contemplates that the first end 805 andsecond end 810 may be configured (e.g., sized and shaped) to accommodateoptical fibers of any diameter, as would be understood by one orordinary skill in the art in light of the present disclosure. By way ofexample, the first end 805 may be configured to receive POFs with adiameter of approximately 1 mm while the second end 810 may beconfigured to receive SMFs with a diameter of approximately 125 μm.Additionally, the opto-mechanical coupler 800 may be configured tooperate with optical signals at a nominal wavelength of 1310 nm and/or,alternatively, at nominal wavelengths of 850 nm and 1550 nm. Althoughdescribed in conjunction with optical signals at a wavelength of 1310nm, 850 nm, and/or 1550 nm, the present disclosure contemplates thatsmall variations in wavelength are common in optical transmissions. Thepresent disclosure contemplates utilizing optical signals at anywavelength as would be suitable for transmission via one or more POFs,SMFs, or MMFs.

With reference to FIG. 12, an opto-mechanical coupler according to oneembodiment is illustrated. As shown in FIG. 12, the opto-mechanicalcoupler 1200 may have a first end 1205, a second end 1210, a top surface1215, a bottom surface 1300 (shown in FIG. 15), a reflective surface1220, an aperture 1230, and a through-hole 1225. As described in greaterdetail below, the first end 1205 may define an aperture 1230 such thatthat one or more optical fibers may be properly aligned with thereflective surface 1220 to transmit or receive optical signals.

With continued reference to FIG. 12, the first end 1205 may beconfigured to receive one or more optical fibers. The optical fibers maybe inserted into the opto-mechanical coupler 1200 through the first end1205 such that an end of each fiber is disposed proximate the reflectivesurface 1220. The first end 1205 may define an aperture 1230 such thatone or more optical fibers may be received by the opto-mechanicalcoupler 1200 and aligned with the reflective surface 1220 to properlytransmit or receive optical signals. As shown in FIGS. 14-15, theaperture 1230 may extend through the body of the coupler, and thediameter of the aperture may vary, such that the aperture may have asmaller proximal diameter 1500 at a location closest to the reflectivesurface 1220 and a larger distal diameter 1505 at a location fartherfrom the reflective surface 1220. In such an embodiment, an opticalfiber may only be inserted into the aperture 1230 a set distance (e.g.,through a predefined length of the aperture) until the aperture 1230narrows to a diameter less than or equal to the diameter of the opticalfiber. This aperture 1230 may be configured such that a POF or SMF of aset diameter may only be inserted into the aperture 1230 to a setdistance; however, because the varying diameters of the aperture 1230are concentric, fibers of any diameter will be secured by the aperture1230 such that a central axis of the core of each type of fiber is atthe proper height for communicating an optical signal via the samereflective surface 1220.

The top surface 1515 and the bottom surface (bottom surface 1300 in FIG.13) may define one or more through-holes 1225, as described above withreference to FIGS. 1-3. The opto-mechanical coupler 1200 may have abottom surface 1300 configured to support a plurality of optical lenses1305. As described above with reference to FIGS. 2-4, a plurality oftransceiver modules may be positioned proximate the bottom surface 1300of the opto-mechanical coupler 1200, such that the optical signals canpass between the transceiver module or system and the respectivereflective surface 1220 via the optical lenses 1305.

In some embodiments, the aperture 1230 may be configured to define afirst distance proximate the first end, where the diameter of theaperture is constant along the first distance to limit the movement ofthe one or more optical fibers 1405 in all but the axial direction(e.g., direction of insertion), such as to facilitate insertion. In suchan embodiment, the aperture may define a second distance closer to thereflective surface 1220 where the diameter of the aperture tapers from alarger distal diameter 1505 to a smaller proximal diameter 1500.

As depicted in FIGS. 12-15, one or more optical fibers may be received,secured, and aligned via the first end 1205 and aperture 1230. Althoughdepicted with optical fibers of a certain diameter in FIG. 12-15, thepresent disclosure contemplates that the first end 1205 and aperture1230 may be configured (e.g., sized and shaped) to accommodate opticalfibers of any diameter, as would be understood by one of ordinary skillin the art in light of the present disclosure. Additionally, theopto-mechanical coupler 1200 may be configured to operate with opticalsignals at a nominal wavelength of 1310 nm and/or, alternatively, atnominal wavelengths of 850 nm and 1550 nm. Although described inconjunction with optical signals at a wavelength of 1310 nm, 850 nm,and/or 1550 nm, the present disclosure contemplates that smallvariations in wavelength may also be accommodated in accordance withacceptable tolerances in the field. Accordingly, the present disclosurecontemplates utilizing optical signals at any wavelength as would besuitable for transmission via one or more POFs or SMFs.

Embodiments of a method of manufacturing opto-mechanical couplers, suchas those described above, are also provided, where the method includesforming a body defining a first end, a second end, a bottom surface, atop surface, and a reflective surface, as described above. At least oneaperture may be defined proximate the first end, wherein the aperture isconfigured to receive one or more optical fibers. A plurality of opticallenses may be supported via the bottom surface of the body, with theoptical lenses configured to allow passage of optical signals travelingin a first direction for transmission to or from a plurality ofoptoelectronic transceivers disposed proximate the bottom surface. Asdescribed above, at least one through-hole may be defined extendingbetween the top surface and the bottom surface, and the through-hole maybe configured to receive a pin therethrough. The reflective surface maybe configured to redirect the optical signals between the firstdirection and a second direction substantially perpendicular to thefirst direction. In this way, the coupler may be configured to positionthe one or more optical fibers along the second direction such that anoptical signal from the plurality of optoelectronic transceivers isdirected into the one or more optical fibers or an optical signalreceived from the one or more optical fibers is directed into theplurality of the optoelectronic transceivers.

In some cases, as described above, the apertures of the first end maycomprise grooves configured to locate each optical fiber at a heightrelative to a first optical path in the second direction. The first endmay be configured to receive via the apertures a first set of one ormore optical fibers having a first diameter. In some embodiments, themethod may further comprise defining additional apertures proximate thesecond end, where the additional apertures are configured to receive asecond set of one or more optical fibers having a second diameter, asshown, for example, in FIG. 8. In this regard, the first diameter andthe second diameter are not equal, such that fibers having differentdiameters may be received by a respective end and apertures of thecoupler, as described above.

In some cases, the apertures of the first end may comprise groovesconfigured to locate each optical fiber at a height relative to a firstoptical path in the second direction, and the apertures of the secondend may comprise grooves configured to locate each optical fiber at asecond height relative to a second optical path in the second direction,wherein the first height and the second height are not equal. Eachaperture of the first end may define a distal diameter and a proximaldiameter, and the proximal diameter may be smaller than the distaldiameter.

Accordingly, the one or more optical fibers may be plastic opticalfibers or single mode (or multi-mode) optical fibers, and the couplermay be configured to receive optical signals having a nominal wavelengthof 850 nm, 1310 nm, and/or 1550 nm.

Many modifications and other embodiments of the inventions set forthherein will come to mind to one skilled in the art to which theseinventions pertain having the benefit of the teachings presented in theforegoing descriptions and the associated drawings. Although the figuresonly show certain components of the apparatus and systems describedherein, it is understood that various other components may also be partof the opto-mechanical coupler and transceiver modules. Moreover,although the examples described herein refer primarily to anopto-mechanical coupler that can accommodate POF and SMF, embodiments ofthe application may be used to accommodate a number of different typesof fiber having different diameters, including POF, SMF, and MMF, amongothers, and embodiments of the invention described herein may be appliedto various optoelectronic systems that use VCSELs, edge emitting lasers,edge emitting silicon phontoics components, collimated VCSELs, LISELs,and other sources to emit light through the fiber optic cables.Therefore, it is to be understood that the inventions are not to belimited to the specific embodiments disclosed and that modifications andother embodiments are intended to be included within the scope of theappended claims. Although specific terms are employed herein, they areused in a generic and descriptive sense only and not for purposes oflimitation.

1. An opto-mechanical coupler comprising: a body defining: a first endand a second end, wherein the first end is configured to receive one ormore optical fibers having a first diameter and the second end isconfigured to receive one or more optical fibers having a seconddiameter; a bottom surface supporting a plurality of optical lenses,wherein the optical lenses are configured to allow passage of opticalsignals traveling in a first direction for transmission to or from aplurality of optoelectronic transceivers disposed proximate the bottomsurface, and a top surface opposite the bottom surface, wherein the bodydefines at least one through-hole extending between the top surface andthe bottom surface, wherein the through-hole is configured to receive apin therethrough; and a reflective surface configured to redirect theoptical signals between the first direction and a second directionsubstantially perpendicular to the first direction, wherein the coupleris configured to position the one or more optical fibers along thesecond direction via a selected one of the first end or the second endsuch that an optical signal from the plurality of optoelectronictransceivers is directed into the one or more optical fibers or anoptical signal received from the one or more optical fibers is directedinto the plurality of the optoelectronic transceivers.
 2. Theopto-mechanical coupler according to claim 1, wherein the first enddefines grooves configured to locate each optical fiber at a heightrelative to a first optical path in the second direction.
 3. (canceled)4. The opto-mechanical coupler according to claim 1, wherein the firstdiameter and the second diameter are not equal.
 5. The opto-mechanicalcoupler according to claim 1, wherein the first end defines groovesconfigured to locate each optical fiber at a height relative to a firstoptical path in the second direction, and wherein the second end definesgrooves configured to locate each optical fiber at a second heightrelative to a second optical path in the second direction, wherein thefirst height and the second height are not equal.
 6. The opto-mechanicalcoupler according to claim 1, wherein the first end further comprises anaperture configured to receive an optical fiber, wherein the aperturedefines a distal diameter and a proximal diameter, wherein the proximaldiameter is smaller than the distal diameter.
 7. The opto-mechanicalcoupler according to claim 1, wherein the one or more optical fibers areplastic optical fibers or single mode optical fibers.
 8. Theopto-mechanical coupler according to claim 1, wherein the coupler isconfigured to receive optical signals having a nominal wavelength of1310 nm.
 9. An opto-mechanical coupler comprising: a body defining: afirst end and a second end, wherein the first end comprises an apertureconfigured to receive one or more optical fibers, wherein the aperturedefines a distal diameter and a proximal diameter, wherein the proximaldiameter is smaller than the distal diameter; a bottom surfaceconfigured to support a plurality of optical lenses, wherein the opticallenses are configured to allow passage of optical signals traveling in afirst direction for transmission to or from a plurality ofoptoelectronic transceivers disposed proximate the bottom surface, and atop surface opposite the bottom surface; and a reflective surfaceconfigured to redirect the optical signals between the first directionand a second direction substantially perpendicular to the firstdirection, wherein the aperture is configured such that the one or moreoptical fibers may be inserted into the aperture a distance based on thediameter of the one or more optical fibers, wherein the one or moreoptical fibers are positioned such that an optical signal traveling inthe second direction from the plurality of optoelectronic transceiversis directed via the reflective surface into the one or more opticalfibers or an optical signal from the one or more optical fibers isdirected via the reflective surface into the plurality of theoptoelectronic transceivers.
 10. The opto-mechanical coupler accordingto claim 9, wherein the aperture defines a first distance in the seconddirection having a constant diameter and a second distance in the seconddirection, wherein the diameter of the aperture over the second distanceis tapered between the distal diameter and the proximal diameter. 11.The opto-mechanical coupler according to claim 9, wherein the one ormore optical fibers are plastic optical fibers or single mode opticalfibers.
 12. The opto-mechanical coupler according to claim 9, whereinthe coupler is configured to receive optical signals having a nominalwavelength of 1310 nm.
 13. (canceled)
 14. (canceled)
 15. (canceled) 16.(canceled)
 17. (canceled)
 18. (canceled)
 19. (canceled)
 20. (canceled)21. A method of manufacturing an opto-mechanical coupler comprising:forming a body defining a first end, a second end, a bottom surface, atop surface, and a reflective surface, wherein the first end isconfigured to receive one or more optical fibers having a first diameterand the second end is configured to receive one or more optical fibershaving a second diameter; supporting a plurality of optical lenses viathe bottom surface of the body, wherein the optical lenses areconfigured to allow passage of optical signals traveling in a firstdirection for transmission to or from a plurality of optoelectronictransceivers disposed proximate the bottom surface; and defining atleast one through-hole extending between the top surface and the bottomsurface, wherein the through-hole is configured to receive a pintherethrough; wherein the reflective surface is configured to redirectthe optical signals between the first direction and a second directionsubstantially perpendicular to the first direction, and wherein thecoupler is configured to position the one or more optical fibers alongthe second direction via a selected one of the first end or the secondend such that an optical signal from the plurality of optoelectronictransceivers is directed into the one or more optical fibers or anoptical signal received from the one or more optical fibers is directedinto the plurality of the optoelectronic transceivers.
 22. The methodaccording to claim 21, wherein the first end defines grooves configuredto locate each optical fiber at a height relative to a first opticalpath in the second direction, and wherein the second end defines groovesconfigured to locate each optical fiber at a second height relative to asecond optical path in the second direction, wherein the first heightand the second height are not equal.
 23. The method according to claim21, wherein the one or more optical fibers are plastic optical fibers orsingle mode optical fibers.
 24. The method according to claim 21,wherein the coupler is configured to receive optical signals having anominal wavelength of 1310 nm.
 25. The method according to claim 21,wherein the first diameter and the second diameter are not equal.